Printed circuit board connection assembly

ABSTRACT

In at least one embodiment, a vehicle power module comprises a first printed circuit board (PCB) including a first plurality of electrical components for providing a first voltage and a second voltage. The vehicle power module further comprises a second PCB including a second plurality of electrical components, the second PCB being spaced away from the first printed circuit board and a first connector assembly being coupled to the first PCB and to the second PCB for providing the first voltage to the second PCB. The vehicle power module further comprises a second connector assembly being coupled to the first PCB and to the second PCB for providing the second voltage to the second PCB. The first connector assembly provides the first voltage of up to 14V and the second connector assembly provides the second voltage of 200V or greater.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional application Ser.No. 61/416,968 filed on Nov. 24, 2010, which is hereby incorporated byreference in its entirety.

TECHNICAL FIELD

Embodiments of the present disclosure generally relate to a high powerconnection assembly in a vehicle.

BACKGROUND

Power converters (or other high power devices) employed in vehicleapplications typically consist of discrete components and printedcircuit boards (PCBs). In order to make compact packages, not all of thecomponents are mounted to a single PCB. Two or more PCBs are commonlyneeded to make a complete power converter. Due to this architecture,connections between the PCBs may be needed to electrically couple thecomponents on one PCB to components on another PCB. One method toelectrically couple the PCBs to one another is to use wire with ringterminals and bolts for various high power connections and wiredconnectors for low power signals. A bolted connection between the PCBsmay loosen over time due to vibration, thereby potentially causing afailure (due to overheating of the joint) in the device.

Within the power converters, high power transformer may be necessary toassist in the conversion of AC energy into DC energy such that DC basedpower is stored on one or more batteries in the vehicle. Such high powertransformers may also be used in connection with inverter systems. Thesetransformers may transfer DC energy as provided by the vehicle into ACenergy for the purpose of providing AC power at a power outlet withinthe vehicle such that the vehicle operator may plug a laptop computer orother electric device thereto. These transformers are typically coupledto a PCB (within the high power device) via wires such that the highenergy provided by the transformers are transferred to other high powerelectronics on the PCB. The process of coupling wires to the transformerand to various pads or through-hole connection points on the PCB may becomplicated and may be prone to fail over time.

SUMMARY

In at least one embodiment, a vehicle power module comprises a firstprinted circuit board (PCB) including a first plurality of electricalcomponents for providing a first voltage and a second voltage. Thevehicle power module further comprises a second PCB including a secondplurality of electrical components, the second PCB being spaced awayfrom the first printed circuit board and a first connector assemblybeing coupled to the first PCB and to the second PCB for providing thefirst voltage to the second PCB. The vehicle power module furthercomprises a second connector assembly being coupled to the first PCB andto the second PCB for providing the second voltage to the second PCB.The first connector assembly provides the first voltage of up to 14V andthe second connector assembly provides the second voltage of 200V orgreater.

In at least another embodiment, a vehicle power module is provided. Thevehicle power module comprises a first printed circuit board (PCB)including a first plurality of electrical components for enablingtransmission of electrical power and a second PCB including a secondplurality of electrical components for electrically communicating withthe first plurality of electrical components, the second PCB beingspaced away from the first printed circuit board. The vehicle powermodule further comprises a heat dissipation device positioned betweenthe first PCB and the second PCB for discharging heat from at least oneof the first plurality of electrical components and the second pluralityof electrical components. The vehicle power module further comprises afirst connector assembly including a first male connector and a firstfemale connector, the first connector assembly being coupled to thefirst PCB and to the second PCB for enabling transmission of theelectrical power from the first plurality of electrical components tothe second plurality of electrical components and the female connectorbeing positioned on a side of the second PCB that is opposite to theheat dissipation device.

In at least one embodiment, a vehicle power module is provided. Thevehicle power module comprises a transformer for providing a highvoltage and a printed circuit board (PCB) for receiving the highvoltage. The vehicle power module further comprises a connector assemblycoupled to the transformer and to the PCB. The connector assemblyincluding a male connector; and a female connector including at leasttwo beam terminals defining a cavity to receive the male connector, thefemale connector being arranged to secure the male connector to enabletransfer of the high voltage to the PCB.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments of the present disclosure are pointed out withparticularity in the appended claims. However, other features of thevarious embodiments will become more apparent and will be bestunderstood by referring to the following detailed description inconjunction with the accompany drawings in which:

FIG. 1 generally depicts a first apparatus in accordance to oneembodiment of the present disclosure;

FIG. 2 generally depicts a second connector assembly in more detail inaccordance to one embodiment;

FIG. 3 generally depicts the second connector assembly as positioned ona PCB in accordance to one embodiment;

FIG. 4 generally depicts a second apparatus in accordance to oneembodiment of the present disclosure;

FIG. 5 generally depicts the third connector assembly as positioned onthe PCB and a transformer in accordance to one embodiment; and

FIG. 6 generally depicts another view of the third connector assembly aspositioned on the PCB and on the transformer in accordance to anotherembodiment.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention that may be embodied in variousand alternative forms. The figures are not necessarily to scale; somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

The embodiments of the present disclosure provide for, but not limitedto, male and female connectors (both for high power and low power) thatare soldered to PCBs for electrically coupling the same. These male andfemale connector systems may be fully qualified as separate products. Inaddition, the embodiments of the present disclosure provide for, but notlimited to, coupling various high power components (e.g., a transformeror other suitable device) to the PCB through a connector assembly. Theaforementioned embodiments may, among other things, eliminate bolted orwire connections when stacking PCBs on one another and/or eliminate wireconnections when coupling bigger or heavier high power electricaldevices to the PCB for the purpose of high-energy transfer.

FIG. 1 depicts a first apparatus 10 for use in connection with avehicle. In one example, the apparatus 10 may be implemented as a powermodule that is generally used in connection with a hybrid or electricvehicle. It is recognized that the apparatus 10 may be used in anydevice that enables the transmission of high voltage energy and/or lowvoltage energy. The apparatus 10 includes one or more printed circuitboards (PCBs) 12 a-12 n (or “12”) and a plurality of electricalcomponents 13 a-13 n (or “13”) positioned respectively thereon. Theplurality of electrical components 13 on the PCB 12 are generally inelectrical communication with one another and enable the transfer ofhigh voltage and low voltage energy within the first apparatus 10.

The PCBs 12 a-12 n are spaced apart from one another and are configuredto transfer electrical signals (e.g., low energy) and/or electricalpower (i.e., high energy) to one another. At least one first connectorassembly 14 and at least one second connector assembly 16 electricallycouple the PCBs 12 a-12 n to one another. The PCBs 12 a-12 n may enablethe transfer of electrical signals (e.g., up to 14 V) via the at leastone first connector assembly 14 and electrical power (e.g., a voltagethat is greater than 200 V (e.g., 800 V, etc.)) via the at least onesecond connector assembly 16. The first apparatus 10 further includes acold plate (or heat dissipation device) 17 that is positioned below thePCB 12 b and above the PCB 12 n. The cold plate 17 is generally part ofa fluid cooling system that operates to cool various electricalcomponents within the first apparatus 10 that generate large amounts ofheat in response to transferring the high amount of energy. Therelevance of the cold plate 17 will be discussed in more detail inconnection with FIG. 3. The heat dissipation device 17 may or may notinclude the use of fluid for purposes of cooling the various electricalcomponents.

Each first connector assembly 14 includes a female connector 18 and amale connector 20 (or pin). Each male connector 20 includes a first end22 and a second end 24. The first end 22 is fixed (soldered) to aparticular PCB 12 while the second end 24 is received and secured by thefemale connector 18. Each female connector 18 is soldered to theparticular PCB 12. The first connector assembly 14 is generallyconfigured to enable the transfer of electrical signals between the PCBs12 a-12 n.

Each second connector assembly 16 includes a female connector 26 and amale connector 28 (or pin). The male connector 28 includes first andsecond ends 30, 32. The first end 30 is fixed (soldered) to the PCB 12while the female connector 26 receives and secures the second end 32.The second connector assembly 16 is generally configured to enable thetransfer of (high) electrical power between the PCBs 12 a-12 n. In oneexample, the second connector assembly 16 is configured to enableanywhere from between 40 to 60 amps of current to pass between the PCBs12 a-12 n. This will be discussed in more detail below.

One or more mechanical supports 34 are provided for supporting PCB 12 awith respect to PCB 12 b and for supporting PCB 12 b with respect to PCB12 n. It is recognized that the size of the mechanical support 34 mayvary based on the desired criteria of a particular implementation. It isalso recognized that the number of the mechanical supports 34 usedwithin the apparatus 10 may vary based on the desired criteria of aparticular implementation.

As depicted, the at least one second connector assembly 16 enables highenergy transfer between the PCBs 12 a-12 n without incorporating variousbolt connections or wire connections therebetween. Such a condition mayincrease connection reliability and reduce process complexity when thefirst apparatus 10 is manufactured. For example, the use of a boltedconnection adds additional joints or connection points which mayincrease the potential for failure at such points. In addition, a boltedconnection generally requires the use of a tool that applies a torquethereto to tighten the connection. The application of torque may not beproperly controlled or there may be over torque conditions that mayjeopardize the physical connection of the bolted connection therebyreducing the integrity of the connection point. Such a condition maylead to undesired open circuits at these points. The use of the firstand the second connector assemblies 14, 16 to couple the PCBs 12 to oneanother does not require special equipment to establish a connection.

FIG. 2 generally depicts the second connector assembly 16 in more detailin accordance to one embodiment. The male connector (pin) 24 isgenerally formed into a blade terminal. The width of the pin 24 may be6.3 mm or greater to enable the transfer of high current energy. Thefemale connector 26 includes a main body 36, at least one boardattachment point 38, and a plurality of beam members 40. Each beammember 40 is compressively biased against one another other at a point40 a.

The pin 24 (when being mated to the female connector 26) is configuredto pass through the board attachment points 38, the main body 36 and atleast a portion of the beam members 40. The pin 26 is slideably receivedby the beam members 40 is engaged at the point 40 c. The pin 24 iscapable of being secured/fastened to the female terminal 26 to enableenergy transfer when coupled and powered.

FIG. 3 generally depicts the second connector assembly 16 as positionedon the PCB 12 in accordance to one embodiment. The PCB 12 generallyincludes a top side 42 and a bottom side 44. The PCB 12 defines aplurality of through holes 46 each being configured to receive arespective board attachment point 38. As shown, the female connector 26is generally inserted into the bottom side 44 of the PCB 12 such thatthe beam members 40 are positioned on the bottom side 44 thereof. ThePCB 12 generally defines a cavity 48 for enabling the pin 24 to passfrom the top side 42 of the PCB 12 to the bottom side 44 such that thepin 24 is received and secured by the beam members 40.

The positioning of the female connector 26 on the bottom side 44 of thePCB 12 may provide an operator an indication as to whether the maleconnector 28 is properly connected to the female connector 18. Forexample, as shown in FIG. 3, the cold plate 17 is generally positionedbetween the PCB 12 b and the PCB 12 n. Due to the position of the coldplate 17 within the first apparatus 10, an operator may have anobstructed view and may not be able to determine if the male connector28 is fully engaged with the female connector 26 (e.g., the operatorwould be performing a blind operation). By positioning the femaleconnector 26 on the bottom side 44, an operator may have an unobstructedview of the connection to ensure such connectors 26, 28 are properlyengaged. In addition, the positioning of the female connector 26 on thebottom side 44 of the PCB 12 may reduce height between the PCBs 12. Sucha condition may decrease the overall package size of the first apparatus10 which may allow for additional space in the vehicle for other vehiclecomponents. Likewise, the positioning of the female connector 26 on thebottom side 44 of the PCB may improve alignment when inserting the maleconnector 24 into the female connector 26.

Each board attachment point 38 generally defines an opening 50. Soldermay be applied to the each board attachment point 38 and is received atthe openings 50 and at the through holes 46 to secure the femaleconnector 26 to the PCB 12. It is recognized that a housing (not shown)may be formed around the female connector 26 to prevent undesiredcontact from other components in the first apparatus 10.

As noted above, the second connector assembly 16 may enable high currenttransfer in the range of 40 to 60 A. It is recognized that the secondconnector assembly 16 may exceed the foregoing current range as notedabove and that such a current range may be limited by the thickness ofthe traces used within the first apparatus 10. Likewise, the currentrange may be limited due to various characteristics of the female andmale connector 26, 28. For example, the overall width of the maleconnector 24 may be increased to enable increased current flow. Inaddition, it is recognized that each board attachment point 38 on thefemale connector 26 generally enables anywhere from 10-15 A of currentflow. Increasing the overall number of board attachment points 38 on thefemale connector 26 may increase the current carrying capabilitythereof.

FIG. 4 generally depicts a second apparatus 60 in accordance to oneembodiment. The second apparatus 60 may be implemented as a power modulethat is generally used in connection with a hybrid or electric vehicle.It is recognized that the apparatus 60 may be used in any device thatenables the transmission of high voltage energy and/or low voltageenergy. In one example, the first apparatus 10 and the second apparatus60 may be implemented together, within a power module for enabling thetransmission of high voltage energy and/or low voltage energy.

The second apparatus 60 includes the PCB 12, a plurality of electricalcomponents 62, and a transformer 64. The plurality of electricalcomponents 62 interface with the transformer 64 to provide the highvoltage energy. The second apparatus 60 includes at least one thirdconnector assembly 66. Each third connector assembly 66 includes afemale connector 68 and a connector housing 70 formed around the femaleconnector 68. A plurality of male connectors (or pins) 72 is positionedon the transformer 64. Each female connector 68 is configured to receivea corresponding male connector 72 so that an electrical connection isformed with the plurality of electrical components 62 and the PCB 12. Itis recognized that the number of third connector assemblies 66 and themale connectors 72 may vary based on the desired criteria of aparticular implementation.

The use of the third connector assembly 66 and the male terminal 66 mayobviate the need for conventional connection methods such as wire orbolted connections to couple the PCB and the transformer. The use of thethird connector assembly 66 may simplify the assembly of the secondapparatus 60. Such a condition may also increase the overall reliabilityof the second apparatus 60. Additional conventional systems may utilizea transformer that is embedded within the PCB. This type of animplementation may increase manufacturing complexity and increase cost.

The male connector (pin) 72 is generally L-shaped. The width of each pin72 may be 6.3 mm or greater to enable the transfer of high current. Aseal 74, such as shrink-wrap or other suitable mechanism is formed overat least a portion of the male connector 72. The seal 74 generallyprovides voltage isolation between the connectors (e.g., the femaleconnector 68 and/or the male connector 72) and the housing 70. It isrecognized that the seal 74 may be implemented as a molded plastic partor other suitable mechanism.

FIGS. 5-6 generally depict the third connector assembly 66 as positionedon the PCB 12 in accordance to one embodiment. The female connector 68generally includes beam terminals 76 that are positioned opposite oneanother for defining a cavity to receive the male connector 72. Thefemale connector 68 includes an attachment point 78 that is secured to acavity in the PCB 12. As shown, the female terminal 68 is generallypositioned on the top side 42 of the PCB 12 while the attachment point78 protrudes through the bottom side 44 of the PCB 12.

The embodiments of the present disclosure may provide a high powerconnection system assembly that may be used to connect (i) a number ofPCBs that transfer large amounts of electrical power and/or (ii) atransformer to a PCB that also provides a large amount of electricalpower. The high power connection assembly may (1) provide male andfemale connectors that maintain correct contact pressure regardless ofthe assembly procedure, while the quality of bolted connection may varydue to bolt torque; (2) not require special equipment to mate the maleand female connectors while a torque controlled tool may be needed tomake a bolted connection; (3) not require wires when the male and femaleconnectors of the present disclosure are used, this may result in alower manufacturing cost; and (4) not require hand assembly as the maleand female connectors may be soldered to the PCBs using normal PCBsoldering processes. It is recognized that the embodiments of thepresent disclosure may provide for additional aspects that are notdisclosed herein. The aforementioned listing is given to provide asample of various aspects offered by the present disclosure and in noway is to be construed as a complete or exhaustive list.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms of the invention. Rather,the words used in the specification are words of description rather thanlimitation, and it is understood that various changes may be madewithout departing from the spirit and scope of the invention.Additionally, the features of various implementing embodiments may becombined to form further embodiments of the invention.

What is claimed is:
 1. A vehicle power module comprising: a firstprinted circuit board (PCB) including a first plurality of electricalcomponents for providing a first voltage and a second voltage; a secondPCB including a second plurality of electrical components, the secondPCB being spaced away from the first printed circuit board; a firstconnector assembly being coupled to the first PCB and to the second PCBfor providing the first voltage to the second PCB; and a secondconnector assembly being coupled to the first PCB and to the second PCBfor providing the second voltage to the second PCB; wherein the firstconnector assembly provides the first voltage of up to 14V and thesecond connector assembly provides the second voltage of 200V orgreater.
 2. The vehicle power module of claim 1 wherein the secondconnector assembly includes a male connector and a female connector. 3.The vehicle power module of claim 2 wherein the second PCB includes atop side and a bottom side, and wherein the second PCB defines a firstcavity that extends from the top side and the bottom side for enablingthe male connector to protrude through the bottom side.
 4. The vehiclepower module of claim 3 wherein the female connector includes aplurality of beam members positioned on the bottom side for defining asecond cavity and for engaging the male connector on the bottom side. 5.The vehicle power module of claim 4 further comprising a heatdissipation device being positioned adjacent to the top side of thesecond PCB.
 6. The vehicle power module of claim 4 wherein the secondPCB defines a plurality of attachment cavities positioned about thefirst cavity which extend from the top side to the bottom side.
 7. Thevehicle power module of claim 6 wherein the female connector furtherincludes a plurality of board attachment portions, each board attachmentportion being received at a corresponding attachment cavity for securingthe female terminal to the second PCB.
 8. The vehicle power module ofclaim 7 wherein each board attachment portion extends through eachattachment cavity for protruding from the top side of the second PCB. 9.The vehicle power module of claim 7 wherein each board attachment pointgenerally corresponds to a predetermined amount of current that iscapable of being passed through the female connector.
 10. A vehiclepower module comprising: a first printed circuit board (PCB) including afirst plurality of electrical components for enabling transmission ofelectrical power; a second PCB including a second plurality ofelectrical components for electrically communicating with the firstplurality of electrical components, the second PCB being spaced awayfrom the first printed circuit board; a heat dissipation devicepositioned between the first PCB and the second PCB for discharging heatfrom at least one of the first plurality of electrical components andthe second plurality of electrical components; and a first connectorassembly including a first male connector and a first female connector,the first connector assembly being coupled to the first PCB and to thesecond PCB for enabling transmission of the electrical power from thefirst plurality of electrical components to the second plurality ofelectrical components and the female connector being positioned on aside of the second PCB that is opposite to the heat dissipation device.11. The vehicle power module of claim 10 wherein the second PCB includesa first side and a second side, wherein the second PCB defines a firstcavity that extends from the first side and the second side for enablingthe male connector to protrude through the second side, and wherein thesecond side of the second PCB is positioned opposite to the heatdissipation device.
 12. The vehicle power module of claim 11 wherein thefemale connector includes a plurality of beam members positioned on thesecond side for defining a second cavity and for engaging the maleconnector on the second side.
 13. The vehicle power module of claim 11wherein the second PCB defines a plurality of attachment cavitiespositioned about the first cavity which extend from the first side tothe second side.
 14. The vehicle power module of claim 13 wherein thefemale connector further includes a plurality of board attachmentportions, each board attachment portion being received at acorresponding attachment cavity for securing the female terminal to thesecond PCB.
 15. The vehicle power module of claim 14 wherein each boardattachment portion extends through each attachment cavity for protrudingfrom the top side of the second PCB.